Viessmann VITOGAS 100-F Operating instructions

Service instructions
for contractors
VIESMANN
Vitogas 100-F
Type GS1D
Rated heating output of 29 to 60 kW
Gas boiler
Natural gas and LPG version
For applicability, see the last page
VITOGAS 100-F
5692 699 GB 9/2012 Please keep safe.

2
Please follow these safety instructions closely to prevent accidents and mate-
rial losses.
Safety instructions explained
Danger
This symbol warns against the
risk of injury.
!Please note
This symbol warns against the
risk of material losses and envi-
ronmental pollution.
Note
Details identified by the word "Note" con-
tain additional information.
Target group
These instructions are exclusively
designed for qualified personnel.
■ Work on gas equipment must only be
carried out by a qualified gas fitter.
■ Work on electrical equipment must
only be carried out by a qualified elec-
trician.
■ The system must be commissioned by
the system installer or a qualified per-
son authorised by the installer.
Regulations
Observe the following when working on
this system
■ all legal instructions regarding the pre-
vention of accidents,
■ all legal instructions regarding envi-
ronmental protection,
■ the Code of Practice of relevant trade
associations,
■ all current safety regulations as
defined by DIN, EN, DVGW, TRGI,
TRF, VDE and all locally applicable
standards,
■ Gas Safety (Installation & Use) Regu-
lations
– the appropriate Building Regulation
either the Building regulations, the
Building Regulation (Scotland),
Building Regulations (Northern Ire-
land),
– the Water Fittings Regulation or
Water Bylaws in Scotland,
– the current I.E.E. Wiring Regula-
tions.
If you smell gas
Danger
Escaping gas can lead to explo-
sions which may result in serious
injury.
■ Never smoke. Prevent naked
flames and sparks. Never
switch lights or electrical appli-
ances ON or OFF.
■ Close the gas shut-off valve.
■ Open windows and doors.
■ Remove all people from the
danger zone.
■ Notify your gas or electricity
supplier from outside the build-
ing.
■ Shut off the electricity supply to
the building from a safe place
(outside the building).
Safety instructions
Safety instructions
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If you smell flue gas
Danger
Flue gas can lead to life-threat-
ening poisoning.
■ Shut down the heating system.
■ Ventilate the boiler room.
■ Close all doors leading to the
living space.
Working on the system
■ When using gas as fuel, also close the
main gas shut-off valve and safeguard
against unauthorised reopening.
■ Isolate the system from the power sup-
ply and check that it is no longer 'live',
e.g. by removing a separate fuse or by
means of a main isolator.
■ Safeguard the system against unau-
thorised reconnection.
!Please note
Electronic modules can be dam-
aged by electro-static dis-
charges.
Touch earthed objects, such as
heating or water pipes, to dis-
charge static loads.
Repair work
!Please note
Repairing components which ful-
fil a safety function can compro-
mise the safe operation of your
heating system.
Replace faulty components only
with original Viessmann spare
parts.
Ancillary components, spare and
wearing parts
!Please note
Spare and wearing parts which
have not been tested together
with the heating system can com-
promise its function. Installing
non-authorised components and
non-approved modifications/con-
version can compromise safety
and may invalidate our warranty.
For replacements, use only orig-
inal spare parts from Viessmann
or those which are approved by
Viessmann.
Safety instructions
Safety instructions (cont.)
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Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance.......................................... 5
Further details regarding the individual steps....................................................... 6
Troubleshooting
Diagnostic system................................................................................................ 18
Ignition system
Time chart and function........................................................................................ 19
Designs
Burner control connection diagram...................................................................... 21
Draining/frost protection................................................................................... 23
Parts lists............................................................................................................ 24
Commissioning/service reports........................................................................ 28
Specification....................................................................................................... 29
Certificates
Declaration of conformity...................................................................................... 30
Keyword index.................................................................................................... 31
Index
Index
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For further information regarding the individual steps, see the page indicated
Commissioning steps
Inspection steps
Maintenance steps Page
••• 1. Preparing for commissioning and filling the heating
system............................................................................. 6
••• 2. Checking the gas type.................................................... 7
••• 3. Changing the gas type (if required).............................. 7
••• 4. Checking the static and supply pressure..................... 8
••• 5. Checking the nozzle pressure....................................... 10
••• 6. Determining the flue gas values.................................... 11
••• 7. Checking the ionisation current.................................... 12
••• 8. Checking the draught..................................................... 12
• • 9. Removing the burner...................................................... 13
• • 10. Checking the burner tubes............................................ 13
• • 11. Checking the pilot burner.............................................. 14
•12. Cleaning the heating surfaces (if required).................. 14
• • 13. Fitting the burner............................................................ 15
••• 14. Checking connections on the water side for tightness
••• 15. Checking the safety equipment
••• 16. Checking firm seating of electrical connections
••• 17. Checking all gas equipment for tightness at operating
pressure........................................................................... 15
••• 18. Checking the external LPG safety valve (if installed)
••• 19. Commissioning the system
••• 20. Checking the closing function of the valves in the gas
train
••• 21. Checking the flue gas monitoring device..................... 16
•22. Instructing the system user........................................... 17
Commissioning, inspection, maintenance
Steps - commissioning, inspection and maintenance
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Preparing for commissioning and filling the heating system
Fill water
!Please note
Unsuitable fill water increases
the level of deposits and corro-
sion and may lead to boiler dam-
age.
■ Flush the heating system thor-
oughly before filling.
■ Only use fill water of potable
quality.
■ An antifreeze additive suitable
for heating systems can be
added to the fill water. The anti-
freeze manufacturer must ver-
ify its suitability.
■ Fill and top-up water with a
water hardness in excess of
the following values must be
softened, e.g. with a small soft-
ening system for heating water.
Total permissible hardness of the fill and top-up water
Total heating
output
Specific system volume
kW < 20 l/kW ≥ 20 l/kW to
< 50 l/kW
≥ 50 l/kW
≤ 50 ≤ 3.0 mol/m3
(16.8 °dH)
≤ 2.0 mol/m3
(11.2 °dH)
< 0.02 mol/m3
(0.11 °dH)
> 50 to ≤ 200 ≤ 2.0 mol/m3
(11.2 °dH)
≤ 1.5 mol/m3
(8.4 °dH)
< 0.02 mol/m3
(0.11 °dH)
> 200 to ≤ 600 ≤ 1.5 mol/m3
(8.4 °dH)
≤ 0.02 mol/m3
(0.11 °dH)
< 0.02 mol/m3
(0.11 °dH)
> 600 < 0.02 mol/m3
(0.11 °dH)
< 0.02 mol/m3
(0.11 °dH)
< 0.02 mol/m3
(0.11 °dH)
1. Check that the installation room vent
is open.
2. Check the pre-charge pressure of the
diaphragm expansion vessel.
If the pre-charge pressure of the dia-
phragm expansion vessel is lower
than the static system pressure, top
up with sufficient nitrogen to raise the
pre-charge pressure 0.1 to 0.2 bar
higher than the static system pres-
sure.
3. Open the check valves (if installed).
Commissioning, inspection, maintenance
Further details regarding the individual steps
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4. Fill the heating system with water and
vent until the fill pressure indicated at
pressure gauge A is 0.1 to 0.2 bar
higher than the pre-charge pressure
of the diaphragm expansion vessel.
Minimum system pressure 0.8 bar;
permissible operating pressure
3 bar.
5. Return the check valves to their oper-
ating position.
Checking the gas type
Note
The boiler is preset in the factory for nat-
ural gas E.
1. Check the gas type and Wobbe index
with your gas supply utility or your
LPG supplier and compare them with
the details on the burner label.
2. If the details do not match, convert
the burner to the available gas type,
in accordance with the information
provided by the gas supply utility or
the LPG supplier.
Conversion kit installation
instructions
3. Record the gas type in the report on
page 28.
Wobbe index ranges
Gas type Wobbe index range Ws
kWh/m3MJ/m3
Delivered condition
Natural gas E 12.0 to 16.1 43.2 to 58.0
After conversion
LPG P 20.3 to 21.3 72.9 to 76.8
Changing the gas type (if required)
Conversion kit installation
instructions
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the static and supply pressure
Danger
CO build-up as a result of incor-
rect burner adjustment can have
serious health implications.
Carry out a CO test before and
after work on gas appliances.
Operation with LPG
Flush the LPG tank twice during com-
missioning or replacement. Vent the tank
and gas connection line thoroughly after
flushing.
A
01. Close the gas shut-off valve.
02. Release screw inside test nip-
ple A on the gas train, but do not
remove it; then connect the pres-
sure gauge.
03. Open the gas shut-off valve.
04. Check the static pressure:
■ Natural gas: max. 25 mbar
■ LPG: max. 57.5 mbar
Record the actual value in the serv-
ice report.
05. Start the boiler.
Note
During commissioning, the boiler
can enter a fault state because of
airlocks in the gas line. You can
reset the burner after approx.
10 seconds. For this, switch the
boiler OFF and ON at the control
unit ON/OFF switch.
06. Check the supply pressure (flow
pressure):
■ Natural gas: 8 to 25 mbar
■ LPG: 27.7 to 57.5 mbar
Note
Use a suitable measuring device
with a resolution of at least
0.1 mbar to check the supply pres-
sure.
Record the actual value in the serv-
ice report.
Note
We recommend that the boiler is
equipped with a gas pressure
switch. During assembly, set the
gas pressure switch to the following
values:
■ Natural gas: 8 mbar
■ LPG: 22 mbar
07. Take action as shown in the follow-
ing table.
08. Switch OFF the control unit ON/OFF
switch (the boiler shuts down).
09. Close the gas shut-off valve.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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10. Remove the pressure gauge and
seal test nipple A with screw.
11. Open the gas shut-off valve and
check test nipple A for gas tight-
ness.
Danger
Gas escaping from the test
nipple leads to a risk of
explosion.
Check the test nipple for gas
tightness.
Supply pressure (flow pressure): Action
Natural gas LPG
Below 8 mbar Below 27.7 mbar ■ Do not commission the boiler
■ Notify your gas supply utility or your
LPG supplier
8 to 25 mbar 27.7 to 57.5 mbar Commission the boiler
Above 25 mbar Above 57.5 mbar ■ Install a separate gas pressure gover-
nor upstream of the system
■ Setting the pre-charge pressure:
20 mbar for natural gas
30 mbar for LPG
■ Notify your gas supply utility or your
LPG supplier
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the nozzle pressure
A
B CD
1. Close the gas shut-off valve.
2. Release the screw inside test nipple
A, but do not remove, then connect
the pressure gauge.
3. Open the gas shut-off valve.
Start the boiler.
4. Check the nozzle pressure.
In case of deviation from the value
in the following table remove pro-
tective cap B.
Adjust the nozzle pressure with
screw C.
Note
Screw D has no function.
5. Check the setting values and record
them in the report.
6. Reposition protective cap B.
7. Switch OFF the system ON/OFF
switch on the control unit (the boiler
shuts down).
8. Close the gas shut-off valve.
9. Remove the pressure gauge and seal
test nipple A with screw C.
10. Open the gas shut-off valve, start
the boiler and check test nipple A
for gas tightness.
Danger
Gas escaping from the test
nipple leads to a risk of
explosion.
Check the test nipple for gas
tightness.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Rated heating output kW 29 35 42 48 60
Natural gas E
Nozzle pressure at 20 mbar
supply pressure mbar 9.3 9.0 9.5 9.8 10.3
Nozzle designation 2.55 2.55 2.55 2.55 2.55
Pilot gas nozzle Type 26-2 26-2 26-2 26-2 26-2
LPG
Nozzle pressure at
37/50 mbar supply pressure mbar 28.2 26.2 26.1 24.7 23.5
Nozzle designation 1.55 1.55 1.55 1.55 1.55
Pilot gas nozzle Type 24 24 24 24 24
Number of burner tubes 4 5 6 7 9
Note
The values in the nozzle pressure table
apply to the following ambient condi-
tions:
■ Air pressure: 1013 mbar
■ Temperature: 15 °C
Wobbe index see page 7
Determining the flue gas values
Danger
CO build-up as a result of incor-
rect burner adjustment can have
serious health implications.
Carry out a CO test before and
after work on gas appliances.
Determine the flue gas values and
record them in the report.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the ionisation current
8888
DBurner control unit
1. Pull ionisation cable C from ionisa-
tion electrode E.
2. Connect the measuring device A as
shown in the diagram:
■Push plug-in adaptor (7 6/4) B
into ionisation cable C.
■Push adaptor cable (7 4/6) F
onto ionisation electrode E.
■Push measuring device plug A
into plug-in adaptor B and adap-
tor cable F.
3. Start the boiler.
4. Check the ionisation current.
■ When the pilot burner is lit:
Min. 1.0 µA
■ When the main burner is lit:
Min. 3.0 µA
5. Record the actual values in the report
on page 28.
Checking the draught
Measure the draught behind the draught
hood in Pa (100 Pa = 1 mbar) and record
it in the service report on page 28.
Note
Required boiler draught: 3 Pa
(0.03 mbar).
The chimney draught must not exceed
10 Pa (0.1 mbar). It may be necessary to
fit a draught stabiliser into the chimney.
(Seek the agreement of your local flue
gas inspector [where appropriate].)
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Removing the burner
1. Pull the plug from burner control unit
A.
2. Undo the fitting on gas supply pipe
B and gas train D.
3. Undo screws C and carefully pull
the burner forward and out.
Checking the burner tubes
1. Check the gas outlets for damage. 2. Clean the burner tubes with com-
pressed air.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the pilot burner
3
7
1. Check ionisation electrode A, pilot
burner B and ignition electrode C
for damage.
2. Check the electrode gaps.
Cleaning the heating surfaces (if required)
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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1. Undo self-tapping screws A and
remove top panel B.
2. Release the spring hooks and
remove thermal insulation mat C.
3. Undo cleaning cover D.
4. Clean the heating surfaces of the
boiler body (with the burner removed)
with the cleaning brush supplied.
!Please note
Cleaning agents containing
potassium destroy the heating
surfaces.
Only use potassium-free
cleaning agents.
5. Remove residues from the bottom
plate.
6. Refit in reverse order.
Fitting the burner
Use new gaskets when fitting the
burner.
Checking all gas equipment for tightness at operating pressure
Danger
Escaping gas can lead to explo-
sions.
Check the tightness of all sealing
faces of gas pipes and fittings at
operating pressure with a foam-
ing test agent (leak detection
spray).
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Checking the flue gas monitoring device
28 40
10
1
10 30 50 70 90 110
Temperature in °C
0.4
0.6
0.8
2
4
6
8
20
Resistance in kΩ
1. Turn OFF the control unit ON/OFF
switch.
2. Pull the flue pipe from the draught
hood.
3. To carry out the function test, cover
the flue outlet at the draught hood
with a suitable object.
4. Start the system.
5. The flue gas monitoring device must
shut down the burner within 2 min.
The burner will then be locked out for
approx. 17 min.
6. ■ Check the flue gas monitoring sen-
sor position if the flue gas monitor-
ing device takes more than 2 min to
shut down the burner.
■ Replace the flue gas monitoring
sensor or the burner control unit if
any of the following faults occur:
– The flue gas monitoring device
does not switch off
– The burner does not start
– The flue gas monitoring sensor is
corroded
– Check the flue gas monitoring
sensor resistance and compare
it with the curve (see diagram
above). Replace the sensor in
case of severe deviation
7. Switch the system OFF.
8. Remove the cover, and push the flue
pipe on to the draught hood.
9. Start the system.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
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Instructing the system user
The system installer should hand the
operating instructions to the system user
and instruct the user in operating the
system.
Commissioning, inspection, maintenance
Further details regarding the individual steps (cont.)
5692 699 GB

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System char-
acteristics
Cause Action
The boiler will
not start
No voltage ■ Check the MCB/fuse and power cable
connections.
■ Check the setting of the switch on the
control unit.
Boiler water tempera-
ture too high
Wait until the boiler water temperature
has dropped by approx. 20 K.
The high limit safety
cut-out has responded
Press the reset button on the control
unit.
The flue gas monitor-
ing device (if installed)
has responded
Wait approx. 17 min:
■ If the boiler then starts automatically,
check the flue pipe and the chimney.
■ If the boiler does not start automatical-
ly, check the flue gas monitoring device
(see page 16).
Strapping plug CN2 is
missing at the burner
control unit
Retrofit strapping plug CN2 or a flue gas
monitoring sensor.
The gas pressure
switch has responded
and interrupted the gas
supply
Check the gas pressure.
Burner control
unit enters a
fault state
No gas available (air in
the supply line)
Reset by switching the control unit ON/
OFF switch ON and OFF.
The pilot burner will not
start
Check the ignition electrode (see
page 14).
Check the gas supply.
Ionisation current too
low or cable break
■ Check the ionisation current: Min.
3 µA when main burner is operational
(see page 12).
■ Remove the pilot burner and check for
damage (see page 14).
Control unit faults:
Boiler control unit service instruc-
tions
Troubleshooting
Diagnostic system
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Time chart
T5T1 T2 T3 T4 T6
P
A
B
C
D
E
F
G
H
AHeat demand
BExternal LPG valve
CGas pressure switch
DIgnition
EPilot gas valve
FIonisation current
GMain gas valve
HFlue gas monitoring device
Intervals
T1 Waiting period 3 s
T2 Pre-ignition time 3 s
T3 Safety time 1 Max. 39 s
T4 Pilot burner stabilising time 6 s
T5 Safety time 2 Max. 3 s
T6 Delay 21 s
Ignition system
Time chart and function
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Function
Pilot gas valve E and external LPG
valve B (if installed) open after a heat
demand A is issued. The gas pressure
switch C (if installed) is switched on.
Gas flows to the pilot burner; at the same
time, ignition D is switched on.
The burner control unit receives an ioni-
sation current F via the ionisation elec-
trode.
After the pilot burner T4 has stabilised,
main gas valve G opens and the burner
ignites.
Note
A reset after a fault shutdown can only
be implemented after at least 10 s have
elapsed. For this, switch the control unit
ON/OFF switch OFF and ON again.
Ignition system
Time chart and function (cont.)
5692 699 GB